TauFactor: An open-source application for calculating tortuosity factors from tomographic data

TauFactor is a MatLab application for efficiently calculating the tortuosity factor, as well as volume fractions, surface areas and triple phase boundary densities, from image based microstructural data. The tortuosity factor quantifies the apparent decrease in diffusive transport resulting from convolutions of the flow paths through porous media. TauFactor was originally developed to improve the understanding of electrode microstructures for batteries and fuel cells; however, the tortuosity factor has been of interest to a wide range of disciplines for over a century, including geoscience, biology and optics. It is still common practice to use correlations, such as that developed by Bruggeman, to approximate the tortuosity factor, but in recent years the increasing availability of 3D imaging techniques has spurred interest in calculating this quantity more directly. This tool provides a fast and accurate computational platform applicable to the big datasets (>10^8 voxels) typical of modern tomography, without requiring high computational power

Additive manufacturing for solid oxide cell electrode fabrication

© The Electrochemical Society.Additive manufacturing can potentially offer a highly-defined electrode microstructure, as well as fast and reproducible electrode fabrication. Selective laser sintering is an additive manufacturing technique in which three-dimensional structures are created by bonding subsequent layers of powder using a laser. Although selective laser sintering can be applied to a wide range of materials, including metals and ceramics, the scientific and technical aspects of the manufacturing parameters and their impact on microstructural evolution during the process are not well understood. In the present study, a novel approach for electrode fabrication using selective laser sintering was evaluated by conducting a proof of concept study. A Ni-patterned fuel electrode was laser sintered on an yttria-stabilized zirconia substrate. The optimization process of laser parameters (laser sintering rate and laser power) and the electrochemical results of a full cell with a laser sintered electrode are presented. The challenges and prospects of using selective laser sintering for solid oxide cell fabrication are discussed

Characterising the distribution of methane and carbon dioxide emissions from the natural gas supply chain

Methane and CO2 emissions from the natural gas supply chain have been shown to vary widely but there is little understanding about the distribution of emissions across supply chain routes, processes, regions and operational practises. This study defines the distribution of total methane and CO2 emissions from the natural gas supply chain, identifying the contribution from each stage and quantifying the effect of key parameters on emissions. The study uses recent high-resolution emissions measurements with estimates of parameter distributions to build a probabilistic emissions model for a variety of technological supply chain scenarios. The distribution of emissions resembles a log-log-logistic distribution for most supply chain scenarios, indicating an extremely heavy tailed skew: median estimates which represent typical facilities are modest at 18 – 24 g CO2 eq./ MJ HHV, but mean estimates which account for the heavy tail are 22 – 107 g CO2 eq./ MJ HHV. To place these values into context, emissions associated with natural gas combustion (e.g. for heat) are approximately 55 g CO2/ MJ HHV. Thus, some supply chain scenarios are major contributors to total greenhouse gas emissions from natural gas. For methane-only emissions, median estimates are 0.8 – 2.2% of total methane production, with mean emissions of 1.6 - 5.5%. The heavy tail distribution is the signature of the disproportionately large emitting equipment known as super-emitters, which appear at all stages of the supply chain. The study analyses the impact of different technological options and identifies a set of best technological option (BTO) scenarios. This suggests that emissions-minimising technology can reduce supply chain emissions significantly, with this study estimating median emissions of 0.9% of production. However, even with the emissions-minimising technologies, evidence suggests that the influence of the super-emitters remains. Therefore, emissions-minimising technology is only part of the solution: reducing the impact of super emitters requires more effective detection and rectification, as well as pre-emptive maintenance processes

Validation of a physically-based solid oxide fuel cell anode model combining 3D tomography and impedance spectroscopy

This study presents a physically-based model for the simulation of impedance spectra in solid oxide fuel cell (SOFC) composite anodes. The model takes into account the charge transport and the charge-transfer reaction at the three-phase boundary distributed along the anode thickness, as well as the phenomena at the electrode/electrolyte interface and the multicomponent gas diffusion in the test rig. The model is calibrated with experimental impedance spectra of cermet anodes made of nickel and scandia-stabilized zirconia and satisfactorily validated in electrodes with different microstructural properties, quantified through focused ion beam SEM tomography. Besides providing the material-specific kinetic parameters of the electrochemical hydrogen oxidation, this study shows that the correlation between electrode microstructure and electrochemical performance can be successfully addressed by combining physically-based modelling, impedance spectroscopy and 3D tomography. This approach overcomes the limits of phenomenological equivalent circuits and is suitable for the interpretation of experimental data and for the optimisation of the electrode microstructure

Real-time monitoring of proton exchange membrane fuel cell stack failure

Uneven pressure drops in a 75-cell 9.5-kWe proton exchange membrane fuel cell stack with a U-shaped flow configuration have been shown to cause localised flooding. Condensed water then leads to localised cell heating, resulting in reduced membrane durability. Upon purging of the anode manifold, the resulting mechanical strain on the membrane can lead to the formation of a pin-hole/membrane crack and a rapid decrease in open circuit voltage due to gas crossover. This failure has the potential to cascade to neighbouring cells due to the bipolar plate coupling and the current density heterogeneities arising from the pin-hole/membrane crack. Reintroduction of hydrogen after failure results in cell voltage loss propagating from the pin-hole/membrane crack location due to reactant crossover from the anode to the cathode, given that the anode pressure is higher than the cathode pressure. Through these observations, it is recommended that purging is avoided when the onset of flooding is observed to prevent irreparable damage to the stack